Layered apparatus and method

ABSTRACT

Aspects of the disclosure are directed to apparatuses and/or methods involving a wall patch. As may be implemented in accordance with one or more aspects characterized herein, a wall patch has a plurality of layers including a base layer having an upper surface and a lower surface, and stacked layers stacked over the upper surface of the base layer. Each stacked layer is stacked on one of the other layers and has an exposed lower surface region that extends laterally beyond the layer upon which it is stacked. Adhesive may operate to adhere the exposed lower surface regions and the lower surface of the base layer may be adhered to a wall surface. The stacked layers, base layer and adhesive to provide a gradient defined by the thicknesses of the layers and adhesive, and defined by the area of the exposed lower surface regions of the stacked layers.

BACKGROUND

A variety of structures such as wall board or cement board are oftensubject to damage. For instance, gypsum-based materials often referredto as drywall, wallboard, and such can be readily damaged due toapplication of force, staining, punctures and other physicalinteractions. Such damage may result in holes, crushed areas, unevensurfaces and other visually perceptible characteristics.

Repairing structures such as wall board that are damaged in this regardcan be challenging. For instance, it may be challenging to provide arepair that is structurally sound yet visually appealing. When patchingholes or recesses, the resulting material is often visible whenrepainted. Furthermore, applying such patches can be time-consuming anddifficult.

These and other matters have presented challenges to repairingstructures, for a variety of applications.

SUMMARY

Various example embodiments are directed to a layered structure, such asa wall patch, its application and its manufacture. Such embodiments maybe useful for addressing issues including those noted above in regard torepairing damaged surfaces. In particular, various embodiments aredirected to a layered structure that facilitates covering or patching ofdamaged surfaces in a manner that mitigates visual detection of thecovered or patched areas of the surfaces.

Aspects of the disclosure are directed to apparatuses and/or methodsinvolving a wall patch. As may be implemented in accordance with one ormore aspects characterized herein, a wall patch has a plurality oflayers including a base layer having an upper surface and a lowersurface, and stacked layers stacked over the upper surface of the baselayer. Each stacked layer is stacked on one of the other layers and hasan exposed lower surface region that extends laterally beyond the layerupon which it is stacked. Adhesive may operate to adhere the exposedlower surface regions and the lower surface of the base layer may beadhered to a wall surface. The stacked layers, base layer and adhesiveto provide a gradient defined by the thicknesses of the layers andadhesive, and defined by the area of the exposed lower surface regionsof the stacked layers.

In certain embodiments, a wall patch includes a base layer of materialhaving upper and lower planar surfaces, and stacked layers of planarmaterial on the upper surface of the base layer. A first one of thestacked layers is stacked on the upper surface of the base layers andthe remaining stacked layers are stacked directly on one of the otherstacked layers, with one or more of the stacked layers having a lowersurface area that is larger than a lower surface area of one of thestacked layers on which it is directly stacked. The patch may be adheredto a wall (or other) surface and around an opening or other regiontherein, by adhering exposed regions of the stacked layers to thesurface around the opening, with the lower surface of the base layerfacing the opening.

The above discussion/summary is not intended to describe each embodimentor every implementation of the present disclosure. The figures anddetailed description that follow also exemplify various embodiments.

BRIEF DESCRIPTION OF FIGURES

Various example embodiments may be more completely understood inconsideration of the following detailed description and in connectionwith the accompanying drawings, in which:

FIG. 1 shows an apparatus as may be implemented in accordance with oneor more embodiments;

FIG. 2 shows a cross-sectional view of a patch having respective layersof film coated with adhesive, as may be implemented in accordance withone or more embodiments;

FIG. 3 shows patch having a plurality of film layers, as may beimplemented in accordance with one or more embodiments;

FIG. 4 shows a top view of a patch having a plurality of film layers, asmay be implemented in accordance with one or more embodiments;

FIG. 5 shows a cross-sectional view of a patch having a plurality offilm layers, as may be implemented in accordance with one or moreembodiments;

FIG. 6 shows a cross-sectional view of a patch having a plurality offilm layers and its application to a wall board, as may be implementedin accordance with one or more embodiments;

FIG. 7 shows rectangular patch/joint tape having a plurality of filmlayers, as may be implemented in accordance with one or moreembodiments;

FIG. 8 shows a joint tape having a plurality of film layers, as may beimplemented in accordance with one or more embodiments;

FIG. 9 shows a roll of patching material having a plurality of filmlayers, as may be implemented in accordance with one or moreembodiments; and

FIG. 10 shows a joint tape intersection having a plurality of filmlayers, as may be implemented in accordance with one or moreembodiments.

While various embodiments discussed herein are amenable to modificationsand alternative forms, aspects thereof have been shown by way of examplein the drawings and will be described in detail. It should beunderstood, however, that the intention is not to limit the invention tothe particular embodiments described. On the contrary, the intention isto cover all modifications, equivalents, and alternatives falling withinthe scope of the disclosure including aspects defined in the claims. Inaddition, the term “example” as may be used throughout this applicationis by way of illustration, and not limitation.

DETAILED DESCRIPTION

Aspects of the present disclosure are believed to be applicable to avariety of different types of articles of manufacture, apparatuses,systems and methods involving stacked-layer structures, such as may beimplemented to patch openings or damages in a surface such as a wall. Incertain implementations, aspects of the present disclosure have beenshown to be beneficial when used in the context of patching damagedwalls in which stacked layers are used to provide structural supportwhile being tailored to mitigate visual detection of the presence of thepatch. For instance, it has been recognized/discovered that stackedlayers of increasing diameter/perimeter may mitigate the ability of thehuman eye to perceive the patch when applied to a wall and subsequentlycoated (e.g., painted, along with the wall), while providing desirablerigidity. While not necessarily so limited, various aspects may beappreciated through a discussion of examples using such exemplarycontexts.

In certain embodiments, a patch includes a base layer of material andstacked layers of material on an upper surface of the base layer, withone of the stacked layers stacked on the upper surface of the base layerand the remaining stacked layers stacked on one of the other stackedlayers. One or more of the stacked layers has a lower surface area thatis larger than a lower surface area of one of the stacked layers onwhich it is directly stacked. For instance, each respective stackedlayer may have a perimeter that is offset from and that extends around aperimeter of an underlying layer such that the resulting stack has astepped edge.

In some embodiments, the stacked layers provide a stepped gradientdefined by respective perimeters of the stacked layers and increasing indiameter and/or width from the base layer in a direction away from thesurface the wall. Thickness of the stacked layers may be consistent orvaried. In some embodiments, and upper layer of the stacked layers isthicker, relative to underlying layers of generally uniform thickness.For instance, a relatively base layer may be utilized for amenability infollowing an underlying surface, while being thick enough to mitigatewrinkling. In other embodiments, one or more of the stacked layers maybe provided with a thickness that is less than a thickness of one of thestacked layers upon which it is directly stacked, for instance withdecreasing thickness of respective stacked layers. This thicknessvariation may be implemented together with the aforementioned gradient.In some implementations, each of the stacked layers has a lower surfacewith an inner surface region in contact with and adhered to one of thestacked layers on which it is directly stacked, and an outer surfaceregion that extends laterally beyond and around the perimeter of the oneof the stacked layers on which it is directly stacked. The outer surfaceregions define the gradient and have an adhesive which facilitatescoupling to a wall, such as by adhering the outer surface regions ofvarious ones of the stacked layers to the wall around the opening.

The patch may be adhered to a wall (or other) surface and around anopening or other region therein, by adhering exposed regions of one ormore of the stacked layers to the surface around the opening, with thelower surface of the base layer facing the opening. The base layer may,for example, be sized relative to the application such that it coversthe opening, and with a thickness that provides strength relative todeflection in a direction of the opening. As such, the base layer can becentered or otherwise applied to cover the opening to provide desiredstrength. In this context, the opening may be a hole in the wall, adepressed area of the wall, or a damaged area of the wall exhibitingvarying depth. The lower surface of the base layer faces the opening andmay also be in contact with the wall adjacent the opening. Using thisapproach, the base layer and central region of the wall patch mayprovide significant structural rigidity, while stacked layers (as may beof increasing size) facilitate a smooth transition with respect to areasof the surface around the patch and therein mitigate visualdetectability of the application, which mitigating deflection of thewall patch into the opening. Further, an upper/top layer of the patchmay have a surface configured for adhering to paint, facilitatingpainting of the patch and, as may be appropriate, a surrounding surface.For instance, the upper/top layer surface may be coated with a materialhaving matting properties, and may reduce gloss when using a semi-glosspaint. In some embodiments, an acrylic resin treatment is applied to theupper/top layer, for compatibility with paint.

The patch may be implemented in a variety of manners. Materials such aspolyester, polypropylene, polyethylene, metal, cellulose and fiber maybe utilized for respective layers. In some instances, the base layer maybe provided with a less aggressive adhesive, little or no adhesive onthe lower surface thereof, relative to the stacked layers. Suchapproaches may mitigate issues in which the patch may otherwise followcontours or features of an underlying surface. Adhesive thickness may betailored to achieve desired adhesion while adding as little thickness tothe overall apparatus. In addition, adhesion to an underling surfacebeing repaired may be desirably higher relative to adhesion to anunderlying patch layer, such that amount and/or adhesion characteristicsof such adhesive may be tailored relative to a position at which theadhesive is used. For instance, a rigid adhesive (e.g., with high glasstransition temperature (GTT)) may be used to provide strong adhesion toa surface being repaired, and to mitigate darting.

In addition, the respective layers may be formed separately andcombined, such as with two or more layers (as referred to herein) formedas part of a continuous substrate with a thicker portion in a centralarea and stepped edges representing surfaces of the areas (e.g., as madevia deposition, 3D printing or other approach). Where formed on a rollof material, the base and stacked layers may utilize material thatfacilitates flexibility and rapid roll formation.

Patch apparatuses as characterized herein may exhibit a variety ofshapes, to suit particular applications. For instance, round, oval orrectangular layers may be utilized to suit different applications. Edgesof one or more layers may be feathered to increase amalgamation betweenthe surface being repaired and the patch apparatus. As an example, whenrepairing a round hole, a base and stacked layers of a generally roundshape may be utilized to enhance blending of the patch apparatusrelative to a surface being repaired. Accordingly, the shape the patchmay be set/chosen based on the area being repaired.

In a particular application, a rectangular patch type apparatus may beutilized to cover joints between sheets of wall material, such aswallboard or sheetrock. A stepped gradient is provided with layersextending along a length of the patch and with the stepped gradientextending in a perpendicular direction relative to the length, as to beutilized along a length of joint (with a thicker portion at the joint).For application to joint intersections, a patch material having a crossshape may be utilized, with layers similarly providing a steppedgradient in a direction away from the respective joints to be covered,including a thicker portion along the intersecting joints.

In some embodiments, a patch apparatus as characterized herein has aremovable layer on an upper layer thereof, and which is removable afterinstallation. Such a removable layer may facilitate alignment of thepatch relative to a hole or other defect in a surface to be covered,such as by permitting viewing of the underlying (e.g., base) layers andsurface being repaired, after which the upper layer may be removed. Inthis context, adhesion between the removable layer and the rest of thepatch may be set less than adhesion between the rest of the patch andthe surface to which it is applied, to facilitate removal.

In some instances, the removable layer includes a graspable feature suchas a tab coupled to the removable layer to facilitate grasping andremoval of the removable layer. The tab may extend away from an uppersurface area of the removable layer (e.g., laterally when applied to awall surface), such as via placement on a top surface of the removablelayer, or may protrude along an outer perimeter of the removable layer.

A carrier layer may be utilized for supporting a patch apparatus ascharacterized herein, prior to application to a surface. The base layermay be arranged on the carrier layer, with additional layers stackedthereon. Such a carrier layer may, for example, exhibit very lowadhesion characteristics such that the carrier layer may be readilyremoved from exposed adhesive on the underside of layers of the patchapparatus. In some implementations, the carrier layer has a slit orother configuration that facilitates removal without damaging the baseand/or stacked layers.

The patch apparatuses as characterized herein may utilize a variety ofdifferent types of materials. In various embodiments, a base layerincludes a visual aspect, such as a colored, opaque or semi-opaquematerial, reflective portion or marker. For instance, the entire baselayer may be tinted, or markers may be placed along a perimeter or otherareas of the base layer for visualization. Layers stacked on the baselayer exhibit transparency sufficient to allow viewing of the visualaspect of the base layer as well as an underlying surface to which thepatch apparatus is to be applied. This approach may facilitate alignmentof the patch to an underlying surface and a defect therein. Forinstance, when patching a hole in a wall surface that is similar in sizeor smaller in size relative to the base layer, the base layer may becentered on the hole by viewing the wall surface and base layer throughthe overlying layers. The base layer may thus be sized to targetparticular applications, to cover holes or other damage being repaired.

Various embodiments are directed to the application of patchapparatuses, such as those characterized herein. In some instances,thickness of a surface area around an applied patch apparatus is builtup as follows. The patch apparatus is applied with one or more removablelayers, such as characterized above, and a coating is applied to thepatch apparatus (on the one or more removable layers) and to an area ofthe surface adjacent the patch apparatus. After applying the coating, aremovable layer is removed from the patch, thus facilitating applicationof the coating around the patch without necessarily building up thecoating around the perimeter of (or on) the patch. A further coating mayalso be applied. In connection with these embodiments, it has beenrecognized/discovered that applying a coating in this manner can help tovisually mask the presence of the patch underlying a coating (such aspaint).

The following discussion characterizes various embodiments, some ofwhich may be implemented in connection with the figures and relateddiscussion thereof that follows. In accordance with one such embodiment,a wall patch has a base layer having an upper surface and a lowersurface, and stacked layers stacked over the upper surface of the baselayer. Each stacked layer is stacked on one of the other layers and hasan exposed lower surface region that extends laterally beyond the layerupon which it is stacked. The exposed lower surface regions of each ofthe stacked layers may extend laterally beyond and around perimeters ofthe layers over which it is stacked. The wall patch also has an adhesivethat may operate to adhere the exposed lower surface regions and thelower surface of the base layer to a wall surface. The base layer may,for example, exhibit a visual characteristic visible through theoverlying stacked layers. The stacked layers, base layer and adhesiveprovide a gradient defined by the thicknesses of the layers andadhesive, and defined by the area of the exposed lower surface regionsof the stacked layers.

In some implementations, the stacked layers include a top layer that isthicker than the other layers, and each stacked layer exhibits a largersurface area than each layer upon which it is stacked. The layersfurther exhibit a ratio of surface area to thickness that increases foreach layer stacked between the base layer and the top layer, with thetop layer exhibiting a surface area to thickness ratio that is less thanthe surface area to thickness ratio of the layer upon which it isstacked. The layer may, for example, have a thickness of between 2 andthree times the thickness of a thickest one of the other stacked layers.In one such implementation, the top layer has a 6 inch diameter and thepatch exhibits a number of layers having ratios of surface area tothickness of the respective layers that provide an impact resistance of56.6 inch-pounds, applied by a 1.5 inch diameter probe to a center ofthe patch, with the patch being adhered to a wall surface having anopening under the base layer. In another such implementation, the toplayer has a 4 inch diameter and the patch exhibits a number of layershaving ratios of surface area to thickness of the respective layers thatprovide an impact resistance of 23.2 inch-pounds applied by a 1.5 inchdiameter probe to a center of the patch, with the patch being adhered toa wall surface having an opening under the base layer. In yet anothersuch implementation, the top layer has a 2 inch diameter and the patchexhibits a number of layers having ratios of surface area to thicknessof the respective layers that provide an impact resistance of 12.7inch-pounds applied by a 0.84 inch diameter probe to a center of thepatch, with the patch being adhered to a wall surface having an openingunder the base layer.

A variety of numbers of layers may be utilized, such as to use morelayers for patching larger holes. In some implementations, the base andstacked layers total 11 layers, the ratio of surface area to thicknessof the top layer is 14.1 in²/mil, and the exposed lower surface regionof each layer extends 0.150 inches beyond an upper surface of the layerupon which it is stacked. In another implementation, the patch isconfigured to have a total lower surface area that is between two andthree times the lower surface area of the base layer itself. In anotherimplementation, layers exhibit a ratio of surface area to thickness thatincreases for each layer stacked between the base layer and a top one ofthe stacked layers, with the top one of the stacked layers exhibiting asurface area to thickness ratio that is less than the surface area tothickness ratio of the layer upon which it is stacked.

The wall patch may further include a removable layer stacked on a topone of the stacked layers and being operable with the other layers tomitigate visibility of the patch in response to the patch being adheredto a wall surface, a coating being applied onto the removable layer andsurrounding areas of the wall surface and (e.g., after the coating hasdried to touch), the removable layer being removed and another coatingbeing applied to the wall patch and the surrounding areas of the wallsurface.

In accordance with another embodiment, a method of repairing a wall iscarried out as follows. A wall patch is adhered over a damaged region ofa surface of the wall, the wall patch having a plurality of layersincluding a base layer and stacked layers stacked over an upper surfaceof the base layer. Each of the stacked layers is stacked on one of theother layers and has an exposed lower surface region that extendslaterally beyond the layer upon which it is stacked. The layers providea gradient defined by the thicknesses of the layers and adhesive and thearea of the exposed lower surface regions of the stacked layers. Thewall patch is used to resist impact force applied to the patch over thedamaged region. For instance, an impact resistance may be provided atthe damage region that is greater than an impact resistance of anundamaged surface region of the wall (e.g., common drywall). In certainapplications, the wall patch may be used to resist impact force of 56.6inch-pounds (e.g., for a 6 inch patch), of 23.2 inch-pounds (e.g., for a4 inch patch), or of 12.7 inch-pounds (e.g., for a 2 inch patch).

The wall patch may be provided with desirable impact resistance in avariety of manners. In some embodiments, the wall patch is selected andapplied such that a lower surface of the base layer covers the damagedregion and extends beyond the damaged region, and such that a lowersurface area of the patch that is adhered to the wall surface around thedamage is between two and three times the surface area of the patch thatis over the opening. In a particular embodiment, the stacked layersinclude a top layer that is thicker than the other layers, each stackedlayer exhibits a larger surface area than each layer upon which it isstacked, and the plurality of layers exhibit a ratio of surface area tothickness that increases for each layer stacked between the base layerand the top layer. The top layer may exhibit a surface area to thicknessratio that is less than the surface area to thickness ratio of the layerupon which it is stacked.

In accordance with another embodiment, an apparatus includes a baselayer of material having upper and lower surfaces, and stacked layers ofmaterial on the upper surface of the base layer. Each stacked layer isstacked on and adhered to one of the other stacked layers, with one ormore of the stacked layers having a lower surface area that is largerthan a lower surface area of one of the stacked layers on which it isstacked (e.g., the upper of two stacked layers may have a perimeter orother exposed portion exposed portion extends laterally beyond andaround perimeters of the stacked layers and base layer over which it isstacked). For instance, where the base layer and stacked layers havelinear edges, the edges of each layer may be parallel to edges of theother layers with each stacked layer having a perimeter that extendsaround the perimeter of one of the layers on which it is stacked. Thestacked layers may thus increase in diameter relative to underlying onesof the stacked layers. Adhesive on an exposed portion of each layer thatoverlaps an underlying layer may serve to adhere the apparatus,including underlying layers thereof, to a surface. Further adhesive maybe utilized between the layers.

The thickness of each layer, surface area of each layer, and amount ofadhesive between layers may be set to achieve certain characteristics.For instance, the base layer and a plurality of the stacked layers mayhave a common thickness, with a top one of the stacked layers has athickness that is greater than the common thickness. It has beenrecognized/discovered that such an approach can provide desirable impactstrength while also mitigating visibility of the patch afterapplication. Other embodiments utilized layers of differing thickness,for instance decreasing thickness relative to underlying layers. Fordifferently-sized patches, the number of layers and relatedstrength/impact resistance can be balanced with visibility in thisregard.

The stacked layers may have lower surfaces with an inner surface regionin contact with and adhered to one of the stacked layers on which it isdirectly stacked and have an outer surface region that extends laterallybeyond and around the perimeter of the one of the stacked layers onwhich it is directly stacked, and an adhesive on the outer surfaceregion.

In various embodiments, the patch noted above is a wall patch withrespective perimeters of the stacked layers defining a gradientconfigured to reduce an angle of a slope of transition along a radius ofthe wall patch. This facilitates rendering of the patch less detectablerelative to a surrounding wall surface to which the patch is applied(e.g., after painting).

In certain embodiments, an upper one of the stacked layers covers theother stacked layers and base layer and has an upper surface regionconfigured to adhere to a surface coating in response to the surfacecoating being applied to the upper surface region while the apparatus isadhered to a surface. This may, for example, facilitate painting.

A removable layer may be stacked on a top one of the stacked layers, andmay have a tab configured and arranged for removing the removable layerfrom the top one of the stacked layers in response to a pulling forceapplied the tab, therein exposing a top one of the stacked layers. Whereutilized with the aforementioned top layer, the removable layer mayprotect the paintable surface.

In various embodiments, layers of the patch exhibit transparency tofacilitate viewing of a base layer and, for example, alignment to asurface being repaired. For instance, the base layer may exhibit avisual characteristic and the stacked layers may exhibit transparencycharacteristics that facilitate viewing of the visual characteristicthrough the stacked layers. The visual characteristic may provide visualpositioning of the base layer relative to a surface being repaired,through the stacked layers and during application thereof to thesurface.

Certain embodiments further include a carrier material configured tocarry the base layer and stacked layers with the base layer coupledthereto. The carrier material may facilitate separation of the carriermaterial from the base layer for application of the base layer and thestacked layers to a surface.

Various embodiments are directed to methods of making or using patchesas characterized herein. In a particular embodiment, layers of materialare stacked on a base layer of material having upper and lower surfaces,by stacking and adhering a first one of the layers on the upper surfaceof the base layer, and by stacking and adhering each of a pluralityfurther layers on one of the other layers. At least one of the stackedlayers may have a lower surface area that is larger than a lower surfacearea of one of the stacked layers on which it is stacked and havingadhesive on an exposed portion thereof. This approach may also involvealigning so that the adhesive on the exposed portion extends laterallybeyond and around the perimeters of the stacked layers and base layer,such as for adhering to an underlying surface. Each of the plurality offurther layers may be stacked with a perimeter that extends around aperimeter of the underlying layers on which it is stacked.

The base layer may be provided with a visual characteristic, such ascolor or a marker, and with the stacked layers having transparencycharacteristics that facilitate viewing of the visual characteristicthrough the stacked layers. This may facilitate alignment of the baselayer to underlying damage being repaired.

A removable layer may also be stacked on a top one of the stackedlayers. The removable layer may include a tab for grasping and removingthe removable layer from the top one of the stacked layers, in responseto a pulling force applied the tab, and exposing a top one of thestacked layers.

Consistent with the above, the stacked layers may be implemented in avariety of manners. In some implementations, one of the stacked layershas adhesive on an exposed portion thereof extending laterally beyondand around the perimeters of the stacked layers and base layer overwhich it is stacked. As such, the adhesive functions to adhere the oneof the stacked layers, as well as all underlying stacked layers and thebase layer, to the underlying surface. The underlying stacked layers mayalso include adhesive on exposed lower surface regions thereof. Usingsuch approaches, the base layer may mitigate adhering of its lowersurface (and of the apparatus in general) to edges of an opening ordamaged region of the surface to which it is applied. Subsequent ones ofthe stacked layers may increase in diameter and/or decrease in thicknessin a direction away from the underlying base layer. In someimplementations, an upper one of the stacked layers of the apparatuscovers the other stacked layers and base layer and has an upper surfaceregion configured to adhere to a surface coating when applied to theupper surface region while the apparatus is adhered to a surface.

In a particular embodiment, each of a plurality of the stacked layershas a lower surface with an inner surface region in contact with andadhered to one of the stacked layers on which it is directly stacked,and an outer surface region that extends laterally beyond and around theperimeter of all of the stacked layers and the base layer over which itis stacked. Adhesive on the outer surface region adheres the apparatusto a surface, and may be implemented with or without further adhesive onexposed lower surfaces of the underlying stacked layers.

When implemented as a wall patch, respective perimeters of the stackedlayers may define a gradient configured to reduce the angle of the slopeof transition along a radius of the wall patch. Upon application andsubsequent coating, the reduced angle of slope mitigates visualdetection of the wall patch.

FIG. 1 shows an apparatus 100, as may be implemented in accordance withone or more embodiments. While fewer or more layers of varyingcharacteristics may be implemented, the apparatus 100 is depicted withconcentric, planar layers 102-117, with layer 117 acting as a base layerupon which the remaining layers are stacked. Further, a topmostremovable layer 101 (on/behind layer 102 as depicted in dashed lines)may also be utilized to protect and support layer 102.

In connection with various embodiments, it has beenrecognized/discovered that the diameter and thickness of the respectivelayers in the apparatus 100 can be utilized to mitigate visibility ofthe apparatus when implemented as a wall patch for patching a hole orother damage in a wall. In some implementations, the base layer 117 hasa greater thickness relative to ones of the remaining layers, withvarious ones of the remaining layers having similar diameters. In otherimplementations, the larger layers are generally thinner than thesmaller layers, with the thickness of one or more of the layersincreasing as the diameter of the layers decreases. These configurationsof layers thickness provide strength and puncture resistance, whilemitigating visibility of the individual patch layers.

The removable layer 101 may be implemented in a variety of manners. Insome implementations, layer 101 is designed to be removable afterapplying the apparatus as a patch. This layer protects the surface ofthe underlying layer 102 (e.g., which may be prepped for painting orcoating otherwise), and may further provide additional thickness forease of handling and application. In this context, it has also beenrecognized/discovered that use of such a removable layer facilitatesutilization of a very thin (e.g., thickness of ½ of a thousandth of aninch) material for layer (102), which will be the resulting top layer asapplied with layer 101 thereafter removed, which would otherwise bedifficult to handle and apply. It has further been recognized/discoveredthat, applying a coating to the removable layer and surrounding area ofa surface to be repaired, and then subsequently removing the removablelayer and further coating (e.g., painting) helps to hide the patch fromvisual detection. Accordingly, the (resulting) top layer 102 can beimplemented with a very small thickness to mitigate visual detection ofthe wall patch.

The edge of layer 102 may be shaped in a variety of manners, such aswith a pinked cut (e.g., similar to that depicted by way of example inFIG. 1). It has been recognized/discovered that utilization of such apinked cut can help break up the outline of the perimeter of theapparatus when implemented as a patch, and allows an area for an ensuingsurface coating such as paint to collect and help to taper the perimeterof the patch, further decreasing visibility thereof. Furthermore,utilizing a removable layer 101 over the pinked cut layer 102 canprovide support that facilitates application of the apparatus whilemitigating damage to the (ensuing) topmost layer 102 and the pinkedregion, resulting in a smooth and flush application to a surface thatmitigates visual detection relative to adjacent regions of theapplied-to surface (e.g., a wall).

In various implementations, base layer 117 is assembled with a lessaggressive adhesive on a lower surface thereof, which may mitigatesticking of the lower surface of layer 117 (and the apparatus 100overall) to surface characteristics of the surface to which it isapplied, and which may improve visual integration of the apparatus withthe surface being repaired. For instance, when applied for patching adamaged wall in which the base layer 117 is larger than the region ofdamage, use of a less aggressive adhesive on the lower surface of thebase layer prevents the base layer from adhering to features such as anedge of a hole. Adhesive on exposed lower surfaces of one or more of thesubsequent layers 102-116 adheres the apparatus 100 to the surface andmaintains the base layer 117 in place. For instance, an outer region ofthe base layer 117 may be provided with adhesive, where an inner regionof the base layer that is sufficiently large to cover an opening orother damage in the wall is devoid of such adhesive to mitigate couplingof the base layer to features of the opening or other damage.

As may be implemented in a manner consistent with one or moreembodiments characterized above, the base layer 117 may be made of atinted or opaque type material, or may have a marker thereon, withlayers stacked thereon having transparency characteristics thatfacilitate viewing of the base layer 117 and a surface to be repairedthrough the other layers. This facilitates alignment of the base layerrelative to a repair, and also provides a visual check to ensure thatthe base layer 117 will cover an opening or other damage to be repaired.For instance, when applied in a kit concept with respective patches ofdifferent sizes, this approach may be utilized to ensure aproperly-sized patch is applied.

The thickness of the respective layers may be set in accordance withparticular applications. In a specific embodiment, the base layer 117and stacked layers 103-116 have a common thickness, and upper layer 102has a greater thickness. In another specific embodiment, the apparatus100 exhibits dimensions and/or thicknesses as follows. Layers 101-105may be 48 gauge, in which layer 102 may further include apaint-receptive coating or coating receptive to other further surfacetreatments. Layers 106-107 may be 75 gauge, layers 108-109 may be 92gauge, Layers 110 and 111 may be 120 gauge, layers 112 and 113 may be142 gauge, layers 114 and 115 may be 200 gauge, and layers 116 and 117(base layer) may be 300 gauge. With regard to diameter, layers 101-102may be 6.122 in., layer 103 may be 6.042 in., layer 104 may be 5.952in., layer 105 may be 5.862 in., layer 106 may be 5.772 in., layer 107may be 5.682 in., layer 108 may be 5.592 in., layer 109 may be 5.500in., layer 110 may be 5.380 in., layer 111 may be 5.260 in., layer 112may be 5.140 in., layer 113 may be 5.020 in., layer 114 may be 4.840in., layer 115 may be 4.590 in., layer 116 may be 4.340 in., and baselayer 117 may be 3.500 in. Each of layers 102-116 may be implementedwith adhesive on a lower surface thereof, with base layer 117 devoid ofadhesive or with adhesive limited to an upper surface thereof.

FIG. 2 shows a cross-sectional view of a wall patch 200 havingrespective layers of film coated with adhesive, as may be implemented inaccordance with one or more embodiments. The wall patch 200 may, forexample, be implemented in accordance with the apparatus 100 shown inFIG. 1, as a cross-section thereof. The all patch 200 has layers202-217, with some or all of layers 202-216 having an adhesive on alower surface thereof, and base layer 217 having an adhesive that may,for example, be less aggressive than adhesive on other layers. Layer 201is shown as optionally included as a protective layer, which may beutilized on the wall patch 200 through installation thereof over adamaged region of a wall, and then removed. Similar to layer 101 in FIG.1, layer 201 may facilitate application of the wall patch and protectionof layer 202, which can be made very thin via use of removable layer201.

FIG. 3 shows wall patch 300 having a plurality of film layers 301-314,for application to a wall board 320. Region 330, including a lowersurface of base layer 314, may have a less aggressive adhesive, whileregions 331 and 332 include adhesive configured to secure the wall patch300 to a wall surface. Accordingly, as applied to the wall board 320,region 330 is aligned to a damaged area 322 such that the lower surfacethereof does not adhere directly to the damaged area. Adhesive onregions 331 and 332 adheres the wall patch 300 to portions of the wallboard 320 around the damaged area 322. The diameter of the respectivelayers 301-314 increases going away from the wall board 320, which thethickness may be decreased to mitigate visibility of the applied wallpatch.

FIG. 4 shows a top view of a patch 400 having a plurality of filmlayers, as may be implemented in accordance with one or moreembodiments. The patch 400 includes a lower base layer 401, on whichrespective layers 402-411 are stacked, along with a removable top layer420. Each of layers 402-411 may be adhered to an underlying layer uponwhich it is stacked, and each includes a portion thereof that overlapsthe underlying layer. For instance, surface area region “A” along theperimeter of layer 402 overlaps underlying layer 401. The overlappingportions of each layer may similarly include an adhesive, as may theexposed underside of base layer 401 (which may affect coloration/shadingof the base layer). Further, the number of layers 401-411 may beincreased or decreased to suit particular applications, and may be setfor achieving desirable strength while mitigating visibility of thepatch upon application and, where applicable, related finishing.

The underlying surface of one or more layers 401-411 may be coated in anadhesive for adhering to an underlying layer and/or to a surface towhich the patch 400 is to be applied. Such a coating may be uniform ornon-uniform. For instance, adhesive coating on the overlapping portionmay be thicker and/or of a different material relative to adhesivebetween the stacked layers.

Each of layers 402-420 and any adhesive used therewith may betransparent or otherwise permit light to pass such that the base layer401 is visible through the overlying layers. For instance, as shown inFIG. 4, the underlying base layer 401 may be seen through the upperlayers 402-411 (and 420). This may facilitate alignment of the baselayer relative to a damaged surface upon which the patch is to beapplied.

In some implementations, the patch 400 may include a removable carrierlayer 430 upon which the ensuing layers 401-411 and 420 are placed untilapplication. When the patch is to be applied to a surface, the carrierlayer 430 may be removed, exposing adhesive on the undersides of one ormore of layers 401-411.

Removable top layer 420 may be utilized in a variety of manners. In someimplementations, top layer 420 is left in place after applying the patch400 to a surface, while a coating is applied over the top layer and onsurrounding areas of the surface. The top layer 420 may then be removed,for instance after the surrounding surface has dried, exposing layer 411which may then be subsequently coated as well. The top surface of layer411 may be coated for adhesion to a coating material such as paint, forsuch a subsequent coating. With this approach, build-up of the coatingis less on the remaining portion of the patch 400 relative to thecoating applied to the surrounding surface. It has beenrecognized/discovered that such an approach can work to hide visibilityof the patch after application.

In some embodiments, a tab 440 is adhered to and/or part of the toplayer 420, and assists in removal thereof. The tab 440 may have agrasping portion 441 that may be lifted relative to the underlyingsurface of top layer 420, and an adhered portion 442 that is adhered toand/or integrated with the top layer. Accordingly, after application ofthe patch 440 (and, if applicable, after applying a coating to the patchand surrounding area), the grasping portion 441 may be lifted from thesurface of top layer 420, grasped and used to remove the top layer,exposing an upper surface of underlying layer 411. The tab may beimplemented in a variety of manners, for instance with a slit underneathto facilitate removal of the top layer 420, which may for example beperforated in alternating ties (e.g., a 0.131″ tie and 0.375″ slitalternating along a line).

FIG. 5 shows a cross-sectional view of a patch 500 having a plurality offilm layers, as may be implemented in accordance with one or moreembodiments. In certain embodiments, the patch 500 is implemented aspatch 400, with the cross-section as shown corresponding to the stackedlayers in FIG. 4. For instance, base layer 501 may be implemented asbase layer 401 with ensuing layers 502-511 corresponding to similarlynumbered layers 402-411 in FIG. 4, with a removable top layer 520 alsocorresponding to removable layer 420. The patch 500 is also shown withadhesive on the underside of each of layers 501-511 and 520, withadhesive 530 on the underside of layer 502 labeled by way of example.

The layers as depicted in the cross-sectional view of FIG. 5 mayrepresent the corresponding layers in FIG. 4, and may be implementedwith a variety of sizes, thicknesses, amount of adhesive between layers,and structural characteristics. For instance, it has beenrecognized/discovered that, utilizing certain patch thickness todiameter ratios for respective stacked patches can render the patch lessvisible, when applied to a surface. This is useful, for example, tofacilitate patching of damaged surfaces such as walls in a manner thatis not readily detectable by the human eye. The following discussesexemplary embodiments in this context.

In certain implementations, patch 400 has a 6-inch diameter and, whenimplemented to cover a 3 inch damage area (e.g., a 3 inch diameterhole), a ratio of the contact surface area to non-contact surface areafor a surface being repaired is 21.1 to 7.06. A minimum of a 3 to 1ratio of contact versus non-contact area to a surface may be maintainedfor a 6-inch patch.

In another implementation, a patch has a 4-inch diameter and, whenimplemented to cover a 2 inch damage area (e.g., a 2 inch diameterhole), has a ratio of contact surface area to non-contact surface for asurface being repaired of 9.5 to 3.14. A minimum of a 3 to 1 ratio ofcontact surface area to non-contact surface area may also be maintainedfor the 4-inch patch. Such a 4-inch patch may include the same or fewerlayers than depicted in FIG. 4 and characterized above with the 6-inchpatch. The number of layers for the 4-inch patch may be set to achievecertain structural characteristics, such as impact resistance ascharacterized herein, and in some instances is 5 layers having athickness as depicted in the tables below.

In a further implementation, a 2-inch patch for application to a 1 inchdamage area (e.g., a 1″ diameter hole) has a ratio of the contactsurface area to non-contact area of 3.14 to 0.785. A minimum of a 4 to 1ratio of contact surface area to non-contact surface area may bemaintained for the 2-inch patch. Such a 2-inch patch may have fewerlayers than depicted in FIG. 4 and characterized above for the 6-inchpatch. The number of layers for the 2-inch patch may also be set toachieve certain structural characteristics, such as impact resistance ascharacterized herein, and may utilize four layers as characterized inthe table below.

Tables 1-3 below depict respective embodiments involving 6″, 4″ and 2″patches, with ratios of distance to thickness implemented to create agradient that mitigates visibility of the patch after application,relative to surrounding surface area. The layers may, for example, havean adhesive layer of about a 5 mil thickness on an underside thereof. Insome instances, the film thicknesses and diameters as depicted in Table1 are implemented with the layers shown in FIG. 4, with base layer 401utilizing the 3″ diameter layer depicted in the table andsubsequently-stacked layers 402-411 utilizing the indicated layers inthe table with increasing in diameter. Other embodiments may includefewer or more such layers as well.

TABLE 1 Surface Ratio Area SA/thickness FILM DIAMETER (in²) (in2/mil) 2mil 6.000 28.3 14.1 75 GAUGE 5.700 25.5 34.0 75 GAUGE 5.400 22.9 30.5 75GAUGE 5.100 20.4 27.2 75 GAUGE 4.800 18.1 24.1 75 GAUGE 4.500 15.9 21.275 GAUGE 4.200 13.8 18.5 75 GAUGE 3.900 11.9 15.9 75 GAUGE 3.600 10.213.6 75 GAUGE 3.300 8.5 11.4 75 GAUGE 3.000 7.1 9.4

TABLE 2 Surface Ratio Area SA/thickness FILM DIAMETER (in²) (in2/mil) 2mil 4.000 12.6 6.3 75 GAUGE 3.750 11.0 14.7 75 GAUGE 3.500 9.6 12.8 75GAUGE 3.250 8.3 11.1 75 GAUGE 2.000 3.1 4.2

TABLE 3 Surface Ratio Area SA/thickness FILM DIAMETER (in²) (in2/mil)1.5 mil 2.000 3.1 2.1 75 GAUGE 1.750 2.4 3.2 75 GAUGE 1.500 1.8 2.4 75GAUGE 1.000 0.8 1.0

The 2, 4 and 6 inch patches as characterized above may be implemented toachieve certain impact resistance, upon application to a surface andover respective openings of 3 inch, 2 inch and 1 inch, respectively. Forinstance, when the 6 inch patch is applied to cover an opening havingabout a 3 inch diameter, the amount of underlying surface area of thepatch that is adhered to the surface is 2-3 times the amount of surfacearea of the patch over the opening. This adhered surface can providesignificant impact resistance strength. In connection with certainembodiments, it has been recognized/discovered that the arrangement ofnumbers of layers and thicknesses and related ratios of surface area tothickness facilitate high impact resistance. In certain suchembodiments, the 2 inch patch exhibits 12.7 in-lbs impact strength tofailure with a 0.84″ diameter probe applied to the center of the patch.In other such embodiments, a 4 inch patch exhibits 23.2 in-lbs impactstrength to failure with a 1.5″ diameter probe applied to the center ofthe patch. In further such embodiments, a 6 inch patch exhibits 56.6in-lbs impact strength, also with a 1.5″ diameter probe applied to thecenter of the patch.

Table 4 depicts a variety of numbers of layers, related film thicknessranges and diameter ranges, as well corresponding surface area andratios of surface area to thickness, as may be utilized in connectionwith one or more embodiments.

TABLE 4 Surface Ratio Diameter Area SA/thickness FILM (in) (in²)(in2/mil) 1-10 mil  1-10 0.79-78.5 0.08-78.5 0.5-9 mil 0.7-9.7 0.38-73.90.04-148  0.5-9 mil 0.4-9.4 0.13-69.4 0.01-139  0.5-9 mil 0.1-9.10.008-65.0  0.001-130   0.5-9 mil 0.1-8.8 0.008-60.8  0.001-122   0.5-9mil 0.1-8.5 0.008-56.8  0.001-113   0.5-9 mil 0.1-8.2 0.008-52.8 0.001-106   0.5-9 mil 0.1-7.9 0.008-49.0  0.001-98.0  0.1-9 mil 0.1-7.60.008-45.3  0.001-453   0.1-9 mil 0.1-7.3 0.008-41.8  0.001-418   0.1-9mil 0.1-7.1 0.008-38.5  0.001-385  

FIG. 6 shows a cross-sectional view of a patch 600 having a plurality offilm layers 601-611, for application to a wall board 640, as may beimplemented in accordance with one or more embodiments. The patch 600includes a base layer 601 with stacked layers 602-611. These layers may,for example, be implemented with the layers shown in FIGS. 4 and 5, anda further removable layer may be included over layer 611. The wall board640 is shown by way of example with a damaged area 642. However, asimilar approach may be utilized to repair other surfaces. A centralregion 630 of the patch is utilized to cover the damaged area, withregions 631 and 632 corresponding to perimeter areas of the layers601-611 extending down over the edge of the underlying layers foradhering to the surface of the wall board 640.

FIG. 7 shows rectangular patch/joint tape 700 having a plurality of filmlayers, as may be implemented in accordance with one or moreembodiments. The patch/joint tape 700 may, for example, be applied tocover a rectangular or elongated damaged region of a surface, or may beapplied to an elongated joint between surfaces such as a joint betweenwall boards. The patch/joint tape 700 includes a base layer 710 andstacked layers 720-740 that are stacked thereupon. Additional or fewerlayers may be implemented, to suit particular applications. The toplayer 740 is shown with a contoured edge on lateral elongated sidesthereof, by way of example. Such a contoured edge may also be utilizedon the shorter sides (upper/lower sides in FIG. 7). Each layer mayinclude an adhesive for adhering to underlying layers, with exposedregions of each layer (including region 721 of layer 720) having anadhesive for adhering to an underlying surface. Layers 720-740 may havetransparency characteristics that facilitate viewing of underlying baselayer 710 for alignment to a surface to which the patch/joint tape 700is to be applied. In these contexts, the layers shown in FIG. 7 may beimplemented in a manner similar to those characterized in otherembodiments, such as depicted in FIGS. 4-6. Accordingly, other shapesmay be implemented in a similar manner.

FIG. 8 shows a patch/joint tape 800 having a plurality of film layers,as may be implemented in accordance with one or more embodiments. Thepatch/joint tape 800 may, for example, be implemented in a mannersimilar to the patch/joint tape 700 of FIG. 7, with a base layer 810 andstacked layers 820-840 stacked thereupon. The stacked layers 820-840overlap on opposing elongated sides of the base layer 810, and may beimplemented without such overlap on upper edge 801 and lower edge 802.The stacked layers 820-840 are adhered to underlying layers, with alllayers having an adhesive for adhering to an underlying surface. Thisapproach may facilitate, for example, application to wall board jointsin which the patch/joint tape 800 is extended to a feature such as anintersection of a wall and ceiling or floor, or at an intersectionbetween walls that meet at an angle. This approach may also facilitateutilization for multidirectional joints, such as four-way joints wherefour separate sections of wall board meet (e.g., as applicable for usewith the patch shown in FIG. 10, such as with end portions thereoftruncated as depicted via dashed lines 1040-1043 therein).

Another embodiment is directed to a wall patch kit having a plurality ofdifferent wall patches. In one implementation, a wall patch kit includes2″, 4″ and 6″ patches as characterized in the tables above. Such a kitmay further include additional sized diameters, which may have a numberof layers that corresponds to size such that patches of larger size haveadditional layers (e.g., with a similar ratio of number of pads todiameter as in the 6″ patch). In other implementations, a wall patch kithas a variety of shapes, such as those shown in the following figures,square shapes, rectangular shapes (e.g., for electrical box openings),oval shapes, and others.

FIG. 9 shows a roll of patching material 900 having a plurality of filmlayers, as may be implemented in accordance with one or moreembodiments. The patching material 900 may, for example, include layersas depicted in FIGS. 7 and/or 8. In some embodiments, the patchingmaterial 900 has regions for separation to provide a particular lengthof matching material, as shown by way of example with a portion 910remaining on the roll with detached portion 920 separated therefrom.

FIG. 10 shows a joint tape intersection patch 1000 having a plurality offilm layers, as may be implemented in accordance with one or moreembodiments. The patch 1000 includes a base layer 1010 and stackedlayers 1020 and 1030. The (top) layer 1030 is shown with a contourededge. The stacked layers 1020 and 1030 are adhered to an underlyinglayer, and all layers have an adhesive for adhering to a surface, suchas at an intersection of respective wall boards. More or fewer suchstacked layers may be used, and may be implemented in a manner similarto that depicted with other embodiments herein. In some implementations,the patch 1000 is truncated or separable at dashed lines 1040, 1041,1042 and 1043, such as to facilitate utilization with an elongated stripof joint tape/patch such as depicted in FIG. 8. For instance, the jointtape/patch 800 may be aligned such that lower edge 802 of the jointtape/patch 800 is aligned with upper edge 1040 (when truncated) of patch1000. For such application, the number and width of stacked layers inthe patch 1000 may be matched to that of joint tape/patch 800.

Based upon the above discussion and illustrations, those skilled in theart will readily recognize that various modifications and changes may bemade to the various embodiments without strictly following the exemplaryembodiments and applications illustrated and described herein. Forexample, various thicknesses and diameters of layers of an apparatussuch as a wall patch may be implemented to suit particular applications.For instance, the apparatus as depicted in FIG. 1 may be scaled and usedas a wall patch to suit a variety of different types and sizes of walldamage regions. Further, fewer or additional layers may be used as isneeded relative to damage size and related mitigation of visualrecognition of the layers (e.g., additional layers may be utilized for awall patch for patching larger holes or damage regions, to provide adesired edge gradient along the wall patch). Such modifications do notdepart from the true spirit and scope of various aspects of theinvention, including aspects set forth in the claims.

What is claimed is:
 1. A wall patch comprising: a plurality of layersincluding a base layer having an upper surface and a lower surface andstacked layers stacked over the upper surface of the base layer, each ofthe stacked layers being stacked on one of the other layers and havingan exposed lower surface region that extends laterally beyond the layerupon which it is stacked; and adhesive configured to adhere the exposedlower surface regions and the lower surface of the base layer to a wallsurface, the stacked layers being configured and arranged with the baselayer and the adhesive to provide a gradient defined by the thicknessesof the layers and adhesive, and defined by the area of the exposed lowersurface regions of the stacked layers.
 2. The wall patch of claim 1,wherein: the stacked layers include a top layer that is thicker than theother layers; each stacked layer exhibits a larger surface area thaneach layer upon which it is stacked; and the plurality of layers exhibita ratio of surface area to thickness that increases for each layerstacked between the base layer and the top layer, with the top layerexhibiting a surface area to thickness ratio that is less than thesurface area to thickness ratio of the layer upon which it is stacked.3. The wall patch of claim 2, wherein the top layer has a 6 inchdiameter, and wherein the patch exhibits a number of layers havingratios of surface area to thickness of the respective layers thatprovide an impact resistance of 56.6 inch-pounds applied by a 1.5 inchdiameter probe to a center of the patch, with the patch being adhered toa wall surface having an opening under the base layer.
 4. The wall patchof claim 2, wherein the top layer has a 4 inch diameter, and wherein thepatch exhibits a number of layers having ratios of surface area tothickness of the respective layers that provide an impact resistance of23.2 inch-pounds applied by a 1.5 inch diameter probe to a center of thepatch, with the patch being adhered to a wall surface having an openingunder the base layer.
 5. The wall patch of claim 2, wherein the toplayer has a 2 inch diameter, and wherein the patch exhibits a number oflayers having ratios of surface area to thickness of the respectivelayers that provide an impact resistance of 12.7 inch-pounds applied bya 0.84 inch diameter probe to a center of the patch, with the patchbeing adhered to a wall surface having an opening under the base layer.6. The wall patch of claim 2, wherein: the plurality of layers include11 layers; the ratio of surface area to thickness of the top layer is14.1 in²/mil; and the exposed lower surface region of each layer extends0.150 inches beyond an upper surface of the layer upon which it isstacked.
 7. The wall patch of claim 2, wherein the top layer has athickness of between 2 and three times the thickness of a thickest oneof the other stacked layers.
 8. The wall patch of claim 2, wherein thepatch is configured with a total lower surface area that is between twoand three times the lower surface area of the base layer itself.
 9. Thewall patch of claim 1, wherein the patch has a 6 inch diameter andexhibits a number of layers with respective thicknesses that provide animpact resistance of 56.6 inch-pounds to failure applied by a 1.5 inchdiameter probe to a center of the patch.
 10. The wall patch of claim 1,wherein the patch has a 4 inch diameter and exhibits a number of layerswith respective thicknesses that provide an impact resistance of 23.2inch-pounds to failure applied by a 1.5 inch diameter probe to a centerof the patch.
 11. The wall patch of claim 1, wherein the patch has a 2inch diameter and exhibits a number of layers with respectivethicknesses that provide an impact resistance of 12.7 inch-pounds tofailure applied by a 0.84 inch diameter probe to a center of the patch.12. The wall patch of claim 1, wherein the plurality of layers exhibit aratio of surface area to thickness that increases for each layer stackedbetween the base layer and a top one of the stacked layers, with the topone of the stacked layers exhibiting a surface area to thickness ratiothat is less than the surface area to thickness ratio of the layer uponwhich it is stacked.
 13. The wall patch of claim 1, further including aremovable layer stacked on a top one of the stacked layers, theremovable layer being configured and arranged with the plurality oflayers to mitigate visibility of the patch in response to: the patchbeing adhered to a wall surface; a coating being applied onto theremovable layer and surrounding areas of the wall surface; the removablelayer being removed; and another coating being applied to the wall patchand the surrounding areas of the wall surface.
 14. The wall patch ofclaim 1, wherein the exposed lower surface regions of each of thestacked layers extends laterally beyond and around perimeters of thelayers over which it is stacked.
 15. The wall patch of claim 1, whereinthe base layer exhibits a visual characteristic and the stacked layersexhibit transparency characteristics that facilitate viewing of thevisual characteristic through the stacked layers.
 16. A method ofrepairing a wall, the method comprising: adhering a wall patch over adamaged region of a surface of the wall, the wall patch having aplurality of layers including a base layer and stacked layers stackedover an upper surface of the base layer, each of the stacked layersbeing stacked on one of the other layers and having an exposed lowersurface region that extends laterally beyond the layer upon which it isstacked, therein providing a gradient defined by: the thicknesses of thelayers and adhesive, and the area of the exposed lower surface regionsof the stacked layers; and using the wall patch to resist impact forceapplied to the patch over the damaged region.
 17. The method of claim16, wherein adhering the wall patch and using the wall patch to resistthe impact force includes providing an impact resistance at the damageregion that is greater than an impact resistance of an undamaged surfaceregion of the wall.
 18. The method of claim 16, wherein the stackedlayers include a top layer that is thicker than the other layers, eachstacked layer exhibits a larger surface area than each layer upon whichit is stacked, and the plurality of layers exhibit a ratio of surfacearea to thickness that increases for each layer stacked between the baselayer and the top layer, with the top layer exhibiting a surface area tothickness ratio that is less than the surface area to thickness ratio ofthe layer upon which it is stacked.
 19. The method of claim 16, usingthe wall patch to resist impact force applied to the patch over thedamaged region includes providing an impact resistance selected from thegroup of: 56.6 inch-pounds, 23.2 inch-pounds, and 12.7 inch-pounds. 20.The method of claim 16, wherein using the wall patch to resist impactforce applied to the patch over the damaged region includes selectingand applying the wall patch such that a lower surface of the base layercovers the damaged region and extends beyond the damaged region, andsuch that a lower surface area of the patch that is adhered to the wallsurface around the damage is between two and three times the surfacearea of the patch that is over the opening.